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Trends in Maintenance, Repair, and Overhaul: From AI Readiness to Digital Traceability

Trends in Maintenance, Repair, and Overhaul: From AI Readiness to Digital Traceability
The Maintenance, Repair, and Overhaul (MRO) sector within aviation experienced notable transformation in 2025 as organizations sought to enhance efficiency and resilience amid increasing operational demands. The industry’s focus shifted decisively toward strengthening data readiness for artificial intelligence (AI), integrating intelligent planning tools, and accelerating digitization—particularly in engine maintenance workflows. These developments marked a strategic pivot toward smarter, data-driven operations and more informed decision-making processes.
Data Readiness and AI Adoption
A central priority for MRO providers in 2025 was unlocking the potential of AI, which necessitated a thorough reassessment of data platforms and the quality of source systems. Organizations undertook comprehensive efforts to collect, govern, and correlate diverse data types, ranging from structured maintenance records to unstructured operational logs. For instance, digital task data extracted from Aircraft Maintenance Manuals (AMM) was systematically linked with Maintenance Planning Documents (MPD) and customer work scopes to generate actionable insights.
Despite the abundance of operational data in aviation, the transition to AI readiness faced significant challenges. Skepticism remained prevalent among airline executives, many of whom recalled earlier disappointments with AI implementations. Consequently, the sector continued to lag in applied AI maturity, resulting in cautious market responses and a measured pace of adoption.
AI-Driven Maintenance Planning
In response to these challenges, MROs prioritized the integration of AI into fleet maintenance planning to enhance operational efficiency. By leveraging historical data alongside operational constraints, AI systems automated repetitive tasks such as night halts and A Checks, while optimizing scheduling based on due dates, work center capacity, fleet routing, and staffing considerations. This evolution facilitated a shift from broad task-level planning to more granular, skill-based subtask assignments, thereby improving productivity and resource utilization.
The competitive landscape responded accordingly, with organizations accelerating their adoption of AI-driven technologies to secure operational advantages and reduce turnaround times. This dynamic signaled a growing recognition within the industry of AI’s capacity to deliver tangible efficiency gains.
Advancing Digitization in Engine MRO
Digitization efforts intensified within engine MRO operations to address challenges posed by rising shop visit volumes, labor shortages, and parts delays. Cloud-native systems became the standard for managing complex work scopes, forecasting parts requirements, and ensuring seamless data exchange with customers and original equipment manufacturers (OEMs). AI solutions were increasingly employed to simulate shop visits, predict material needs, and model cost and margin scenarios, enabling faster turnarounds and enhanced accuracy.
The unveiling of FutureMain’s Vertical AI solution at CES 2026 exemplified this momentum, heralding a new era for industrial maintenance and setting elevated standards for equipment reliability.
Outlook for 2026
Having laid the groundwork in 2025 by strengthening data platforms, automating planning processes, and digitizing workflows, the MRO industry is poised to build on these advances in 2026. AI is expected to evolve from isolated applications into an integral component of the MRO ecosystem, facilitating predictive insights, prescriptive maintenance, and real-time compliance validation. As innovation accelerates, the sector will need to confront persistent skepticism and bridge the gap in AI maturity to fully harness the benefits of digital transformation and traceability.

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